Exhaust connection unit for catalytic converter and manufacturing method of exhaust connection unit for catalytic converter

ABSTRACT

An exhaust connection unit for a catalytic converter for connecting a turbocharger and a warm-up catalytic converter provided in a downstream side of the turbocharger includes a flange of which one end is installed to the turbocharger, and a connection member integrally formed by using a single cylindrical pipe through bending, cutting, and hydro-forming molding, and where one end of the pipe is connected to the other end of the flange and the other end of the pipe is connected to the warm-up catalytic converter.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of priority to Korean Patent Application No. 10-2015-0174456, filed with the Korean Intellectual Property Office on Dec. 8, 2015, the entire contents of which are incorporated herein by reference.

TECHNICAL FIELD

The present disclosure relates to an exhaust connecting unit for a catalytic converter, and a method for manufacturing the exhaust connecting unit. More particularly, the present disclosure relates to an exhaust connection unit for a catalytic converter which connects a turbocharger and a warm-up catalytic converter provided in an exhaust line that discharges exhaust gas to the outside.

BACKGROUND

In general, a turbocharger is provided in a vehicle to achieve a greater output.

An engine adopting the turbocharger inhales and compresses exhaust gas and/or external air by a compressor of the turbocharger, and the supercharged air (i.e., high-temperature compressed air) generated from the compression is supplied to the engine.

Such a turbocharger may be connected with a warm-up catalytic converter through a corn-shaped exhaust connection unit, and the exhaust connection unit serves as a path for supplying exhaust gas to the warm-up catalytic converter.

Here, a conventional exhaust connection unit may include a flange installed in the turbocharger and a connection pipe formed of an upper corn member and a lower corn member which are combined to each other by welding and have the flange installed to a front end thereof by welding.

However, such a conventional exhaust connection unit is excessively welded because the respective constituent elements are combined to each other by welding, and the conventional exhaust connection unit is made of a casting material so as to be durable to high heat such that the weight of the exhaust connection unit is increased.

Further, since a material characteristic may change in the welded portion due to the high-temperature exhaust gas, a leak of the exhaust gas may occur in the welded portion, thereby deteriorating durability and efficiency.

Accordingly, a vehicle provided with the turbocharger needs improvement of a structure of the exhaust connection unit that connects the turbocharger and the warm-up catalytic converter because the vehicle undergoes significant vibrations and temperature variations.

The above information disclosed in this Background section is only for enhancement of understanding of the background of the disclosure and therefore it may contain information that does not form the prior art that is already known in this country to a person of ordinary skill in the art.

SUMMARY

The present disclosure has been made in an effort to provide an exhaust connection line for a catalytic converter, of which a flange and a connection member are made of the same material to connect a turbocharger and a warm-up catalytic converter provided in an exhaust line through which exhaust gas is discharged to the outside, thereby light-weighting the exhaust connection unit, and capable of minimizing a welding portion, thereby preventing a leakage of the exhaust gas and improving durability, and a method for manufacturing the same.

An exhaust connection unit for a catalytic converter according to an exemplary embodiment of the present disclosure is provided to connect the turbocharger and the warm-up converter, and the exhaust connection unit includes: a flange of which one end is installed to the turbocharger; and a connection member integrally formed by using a single cylindrical pipe through bending, cutting, and hydro-forming molding, and of which one end is connected to the other end of the flange and the other end is connected to the warm-up catalytic converter.

The flange may include a connection portion connected to the turbocharger and an insertion portion inserted into the connection member.

A supporting step by which one end of the connection member is supported may be formed between the connection portion and the insertion portion.

The flange may be formed by molding austenite-based carbon alloy steel.

The connection member may be formed by shaping a cylindrical shaped pipe into a “U” through bending-molding, cutting the U-shaped pipe, and then expanding the entire shape and lateral ends of each cut pipe through hydro-forming molding.

At least one sensor installation hole penetrating from the inside to the outside may be formed in the connection member.

The connection member may be made of austenite-based carbon alloy steel.

According to another exemplary embodiment of the present disclosure, a method of manufacturing an exhaust connection unit for a catalytic converter for connecting a turbocharger and a warm-up catalytic converter provided in a downstream side of the turbocharger is provided. The method may include: manufacturing a flange through molding; shaping a center portion of a single cylindrical pipe made of the same material as the flange into the shape of a “U” through bending-molding; cutting the U-shaped pipe to shape the U-shaped pipe into the shape of an “L”; forming a connection member by molding the entire exterior appearance of the pipe after the cutting and expanding lateral ends of the cut pipe through hydro-forming; and coupling the flange to one end of the molded connection member by welding.

The flange and the connection member may be made of austenite-based carbon alloy steel.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an exhaust system to which an exhaust connection unit for a catalytic converter is applied according to an exemplary embodiment of the present disclosure.

FIG. 2 is a perspective view of an exhaust connection unit for the catalytic converter according to an exemplary embodiment of the present disclosure.

FIG. 3 is a cross-sectional view of FIG. 2, taken along the line A-A.

FIG. 4 illustrates a manufacturing process of a connection member applied to the exhaust connection unit for the catalytic converter according to an exemplary embodiment of the present disclosure.

FIG. 5 is a process block diagram of a method for manufacturing an exhaust connection unit for a catalytic converter according to an exemplary embodiment of the present disclosure.

DETAILED DESCRIPTION

An exemplary embodiment of the present disclosure will hereinafter be described in detail with reference to the accompanying drawings.

An embodiment described in this specification, and a configuration shown in the drawing, is merely an exemplary embodiment of the present disclosure and does not represent an entire technical idea of the present disclosure, and thus it should be understood that various equivalents and exemplary variations that can replace the exemplary embodiment may exist and remain within the scope of this disclosure.

The drawings and description are to be regarded as illustrative in nature and not restrictive. Like reference numerals designate like elements throughout the specification.

Further, in the drawings, a size and thickness of each element are represented for better understanding and ease of description. The present disclosure is not limited thereto, and the thickness of several portions and areas may be exaggerated.

In addition, unless explicitly described to the contrary, the word “comprise” and variations such as “comprises” or “comprising” will be understood to imply the inclusion of stated elements but not the exclusion of any other elements.

In addition, the terms “ . . . unit”, “ . . . means”, “-er”, and “member” described in the specification mean a unit of a configuration for processing at least one function and operation.

FIG. 1 is a perspective view of an exhaust system to which an exhaust connection unit for a catalytic converter is applied according to an exemplary embodiment of the present disclosure, FIG. 2 is a side view of an exhaust connection unit for the catalytic converter according to an exemplary embodiment of the present disclosure, and FIG. 3 is a cross-sectional view of FIG. 2, taken along the line A-A.

Referring to FIG. 1, an exhaust system to which an exhaust connection unit 100 for a catalytic converter is applied may include an engine 10, a turbocharger 20, a warm-up catalytic converter 30 and a muffler 40.

Exhaust gas discharged from the engine 10 may flow into the turbocharger 20 through an exhaust manifold, and exhaust gas discharged through an outlet of the turbocharger 20 may be supplied to the warm-up catalytic converter 30 through the exhaust connection unit 100.

The exhaust gas discharged from the warm-up catalytic converter 30 may be discharged to the outside of the vehicle through the muffler 40. A function of the warm-up catalytic converter 30 is known in the art, and therefore no further description will be provided.

The exhaust connection unit 100 for the catalytic converter may be applied to connect the turbocharger 20 and the warm-up catalytic converter 30 disposed in a lower side of the turbocharger 20.

Here, the exhaust connection unit 100 for the catalytic converter according to an exemplary embodiment of the present disclosure may include a flange 110 and a connecting member 120.

The flange 110 may be installed to the turbocharger through one end thereof through bolt engagement.

The flange 110 may be formed by molding austenite-based carbon alloy steel.

Such a flange 110 may include a connection portion 111 connected to the turbocharger 20 and an insertion portion 114 integrally extended from the connection portion 112 and inserted into the connecting member 120.

An exterior diameter of the insertion portion 114 may be smaller than an interior diameter of the connection member 120 such that the insertion portion 114 can be inserted into one end of the connection member 120. In addition, the insertion portion 114 may be coupled to the connection member 120 by welding while being tightly fitted into the connection member 120.

The insertion portion 114 may be dually overlapped with the connection member 120 so as to provide a heat blocking function between the flange 110 and the connecting member 120.

Accordingly, one end portion of the connecting member 120 can be prevented from being directly exposed to high-temperature exhaust gas. Thus, thermal deformation and leakage of exhaust gas at one end portion of the connection member 120 coupled with the flange 110 can be prevented, thereby improving durability and efficiency.

Here, a support step 116 by which one end of the connection member 120 is supported may be formed between the connection portion 112 and the insertion portion 114. When the insertion portion 114 is inserted into the connection member 120, the support step 116 may contact one end of the connection member 120 so that it can be determined whether or not the insertion portion 114 is completely inserted.

In addition, the connecting member 120 may be integrally formed through bending, cutting and/or hydro-forming a shape of a single cylindrical pipe, and one end of the connection member 120 may be connected to the other end of the flange 110 and the other end of the connection member 120 may be connected to the warm-up catalytic converter 30.

FIG. 4 illustrates a process for manufacturing the connection member applied to the exhaust connection unit for the catalytic converter according to an exemplary embodiment of the present disclosure.

Referring to FIG. 4, a cylindrical-shaped straight line pipe may be bending-shaped (S1) such that a center portion of the connection member 120 is U-shaped (S2). After that, the center of the U-shaped connection member 120 may be cut into two parts (S3), and each of the two parts may be cut and thus become L-shaped (S4).

Then, the L-shaped pipe after completion of cutting may be hydro-forming shaped so as to expand the entire shape and lateral ends of the pipe (S5).

Here, two sensor mounting holes 122, each penetrating to the outside from the inside, may be provided in the connection member 120. A sensor (not shown) that senses a characteristic of exhaust gas may be installed in the sensor mounting hole 122.

The connection member 120 configured as above may be made of austenite-based carbon alloy steel.

Hereinafter, a method for manufacturing the exhaust connection unit for the catalytic converter, configured as above according to an exemplary embodiment of the present disclosure will be described in detail.

FIG. 5 is a process block diagram of a method for manufacturing an exhaust connection unit for a catalytic converter according to an exemplary embodiment of the present disclosure.

Referring to FIG. 5, a method for manufacturing an exhaust according to an exemplary embodiment of the present disclosure may include manufacturing the flange 110 through molding using austenite-based carbon alloy steel (S10) and bending-molding a center portion of a single cylindrical pipe made of austenite-based carbon alloy steel, which may be the same material as the austenite-based carbon alloy steel (S20), into the shape of “U”.

Next, the U-shaped cylindrical pipe may be cut two times from lateral ends of the pipe to make the shape of the pipe sections an “L” shape after the bending molding (S30).

The entire exterior shape of the L-shaped pipe may be molded through hydro forming, and the lateral ends of the L-shaped pipe may be expanded such that the connection member 120 is manufactured (S40).

The flange 110 may be coupled to the connection member 120 by welding while the insertion portion 114 is inserted into one end of the connection member 120 (S50) such that the exhaust connection unit 100 is manufactured.

Thus, when the exhaust connection unit 100 for the catalytic converter and the method for manufacturing the same according to an exemplary embodiment of the present disclosure is applied, the flange 110 and the connection member 120 may be made of the same material so as to connect the turbocharger 20 and the warm-up catalytic converter 20 provided in the exhaust line through which the exhaust gas is discharged to the outside such that the weight of the exhaust connection unit 100 can be decreased, and a welding portion can be minimized, thereby preventing a leakage of exhaust gas and improving durability and efficiency.

In addition, the connection member 120 may be formed to be integral to the flange 110 by using a single cylindrical-shaped pipe through bending molding and hydro-forming molding such that formability and productivity can be further improved compared to a conventional art.

Further, a welding process may be omitted, except for molding of the flange 110, and accordingly, heat damage and a change in physical properties of the connection member 120 can be prevented.

While this disclosure has been described in connection with what is presently considered to be practical exemplary embodiments, it is to be understood that the disclosure is not limited to the disclosed embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims. 

What is claimed is:
 1. An exhaust connection unit for a catalytic converter for connecting a turbocharger and a warm-up catalytic converter provided in a downstream side of the turbocharger, comprising: a flange of which one end is installed to the turbocharger; and a connection member integrally formed by using a single cylindrical pipe through bending, cutting, and hydro-forming molding, and where one end of the pipe is connected to the other end of the flange and the other end of the pipe is connected to the warm-up catalytic converter.
 2. The exhaust connection unit for the catalytic converter of claim 1, wherein the flange comprises: a connection portion connected to the turbocharger; and an insertion portion inserted into the connection member.
 3. The exhaust connection unit for the catalytic converter of claim 2, wherein a supporting step, by which one end of the connection member is supported, is formed between the connection portion and the insertion portion.
 4. The exhaust connection unit for the catalytic converter of claim 1, wherein the flange is formed by molding austenite-based carbon alloy steel.
 5. The exhaust connection unit for the catalytic converter of claim 1, wherein the connection member is formed by shaping a cylindrical shaped pipe into a “U” through bending-molding, cutting the U-shaped pipe and then expanding the entire shape and lateral ends of each cut pipe through hydro-forming molding.
 6. The exhaust connection unit for the catalytic converter of claim 1, wherein at least one sensor installation hole penetrating from the inside to the outside is formed in the connection member.
 7. The exhaust connection unit for the catalytic converter of claim 1, wherein the connection member is made of austenite-based carbon alloy steel.
 8. A method of manufacturing an exhaust connection unit for a catalytic converter for connecting a turbocharger and a warm-up catalytic converter provided in a downstream side of the turbocharger, comprising: manufacturing a flange through molding; shaping a center portion of a single cylindrical pipe, made of the same material as the flange, into the shape of a “U” through bending-molding; cutting the U-shaped pipe to shape the U-shaped pipe into the shape of an “L”; forming a connection member by molding the entire exterior appearance of the pipe after the cutting step, and expanding lateral ends of the cut pipe through hydro-forming; and coupling the flange to one end of the molded connection member by welding.
 9. The method for manufacturing the exhaust connection unit for the catalytic converter of claim 8, wherein the flange and the connection member are made of austenite-based carbon alloy steel. 